There is a wide range of production methods for stainless steel channels and angle bars, covering the demand. Which performance to use can be established according to the following differentiation.
Press Brake (Cold Forming)
Press brake profiles are made of flats that are mechanically deformed at ambient temperature to the desired shape. This production method is also defined as “cold forming“. Very common shapes for structural application are channels and angle bars.
There are also square and rectangular hollow sections but these are within a category by its own.
The process of press braking
Press braking is a very cost efficient and quick production method. The generally used raw materials are slit or sheared flats from coil or plate.
The press brake production method is characterized by bending parts of the flat to a specific angle with a strong press. A fin is pushing the flat into a groove at the position of the bending angle. The opening of the groove defines the radius of the angle.
Limitations for press brake sections
Of course there are limitations on the bending radius. These are related to the material (mechanical properties), to the material thickness and to the power of the press.
The length of the section depends on the length of the press. Generally they are up to seven or eight meters, but also twelve to 13 meter presses can be found.
The dimensional range is quite flexible. Limits are given by the flange lengths; short flange lengths are not always possible. Of course the wall thickness is constant for both web and flanges.
Another achievement of this production method are good tolerances. Press brake angle bars are lighter due rounded corners. As well as are channels, with the same size as a hot rolled or laser welded section.
Consequences of the cold forming
The rounded corners also have a negative aspect: as they hinder the fixation close to the corner, the most rigid part of the section, of bolts and nuts, welded fins or stud-bolts.
Another side effect of the cold forming production method are the tensions that are generated within the material. This is not an issue as long as there is no release of this internal stress. Once the cold formed sections are heated, the internal tensions are released and the section gets seriously deformed loosing straightness and being twisted. This happens for example while welding fins, stiffeners or stud-bolts on it or due to machining,
For this reason, the press brake production method is a cost efficient, but technically suboptimal solution when used i.e. by producing pipe racks or welded supports.
Hot rolled stainless steel sections
On the other hand, there are hot rolled angle bars and channels. These are available in standard length of six meters and generally only in the austenitic stainless steel grades 304 (1.4301/1.4307) and 316L/Ti (1.4404/1.4571).
There is a wide range of sizes, but no specialties are available.
These sections are annealed and do have an external corner as well as an internal radius. Almost no stress release can be observed when welding or machining the sections.
This is the most economical production method. This material is generally available from stock
Characteristics of the hot rolling
- Available in a wide range of standard sizes, but no custom shapes
- Annealed with external and internal radii for improved performance
- Economical and often available from stock.
Limitations of the hot rolling
- Standard bar length limited to 6 meters.
- Restricted material grades (mainly common austenitic stainless steels)
- No special dimensions or shapes possible.
Laser welded channels and angles
Laser welding is the most flexible method, though also the most expensive. It is ideal for custom projects where precision and design freedom are priorities.
Advantages
- Freedom in shape design and dimensions.
- Possibility of combining different thicknesses for web and flanges.
- Bar lengths up to 16 meters.
- Capability to process almost all stainless steel grades (except martensitic steels).
- Option to combine different grades (“black” and “white” combinations).
- Minimal internal weld bead and sharp edges.
- Very tight dimensional tolerances.
Technical Benefits
Contrary to the press brake production method, almost no stress is introduced into the material, so no uncontrolled tensions will be released when heated due to welding or machining.
The laser welded channels and angle bars come with very tight tolerances. They are sharp-edged and have a minimal internal weld bead.
All these different production methods show their advantages and weak points. But summarized, they all ensure a high level of availability of stainless steel sections satisfying the individual project specific needs.
Comparison Table: Main Production Methods
| Method | Advantages | Limitations | Typical Applications |
|---|---|---|---|
| Press Brake (Cold Forming) |
– Cost-effective and fast – Good dimensional tolerances – Flexible length (up to ~13 m) |
– Rounded corners may hinder fittings – Internal stresses can cause deformation when heated – Constant wall thickness only |
Structural channels, angle bars, general-purpose framing, projects with moderate precision requirements |
| Hot Rolled |
– Economical for standard profiles – Minimal stress during processing – Stock availability in common grades |
– Length limited to 6 m – Restricted grades and sizes – No custom shapes |
Standard construction, general infrastructure, applications needing robust but standard dimensions |
| Laser Welded |
– Highest design flexibility – Precise tolerances and sharp edges – Can mix grades and thicknesses – Lengths up to 16 m |
– Higher cost compared to other methods – Not suitable for martensitic grades |
Architectural features, custom engineering solutions, high-precision structural components |
Summary
By comparing these three main production methods Press Brake, Hot Rolled, and Laser Welded engineers and designers can make informed decisions based on cost, precision, flexibility, and project-specific technical requirements. Montanstahl provides expert advice and production capabilities to match the right method to each application.